Injector installation (4JJ3 with DPD)

Part name

Tightening torque

3: 26 N・m { 2.7 kgf・m / 19 lb・ft }

9: 44 N・m { 4.5 kgf・m / 32 lb・ft }

11: 44 N・m { 4.5 kgf・m / 32 lb・ft }

12: 8 N・m { 0.8 kgf・m / 71 lb・in }

1) Apply engine oil to the O-ring.

2) Install the O-ring to the injector.

3) Clean the cylinder head installation surface and injector.

4) Drop the gasket into the port on the cylinder head side.

5) Check that the gasket has been inserted based on the nozzle height using the injector.

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6) Install the injector clamp to the injector.

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7) Apply engine oil to the threaded portions and seating surfaces of the bolts.

8) Install the injector and injector clamp to the cylinder head.

9) Temporarily tighten the injector clamp bolt to the cylinder head.

1. When replacing the injector

Erase the old cylinder number ID code on the Injector ID Code label attached to the cylinder head cover with a black pen, etc.

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1) Record the Injector ID Code of the new injector.

The correct order of the ID codes shown in the following injector illustration is as follows.
A9 D7 D3 DE CA DB DC D8 U5 CE EF D5 D4 00 00 93

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1) Apply engine oil to the threaded portions of the sleeve nuts on the injector side, as well as the injector O-rings.

2) Temporarily tighten the injection pipes to the common rail (fuel rail) and injectors by hand until the sleeve nuts can no longer turn.

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3) Temporarily tighten the clip to the injection pipe.

4) Final tighten the injector clamp bolt to the cylinder head.

Tightening torque: 26 N・m { 2.7 kgf・m / 19 lb・ft }

5) Final tighten the injection pipes to the injectors and common rail (fuel rail).

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Injector side

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Common rail (fuel rail) side

6) Securely tighten the clip to the injection pipe.

Tightening torque: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

1) Install the leak-off pipe to the inlet manifold.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Connect the 2 leak-off hoses to the leak-off pipe.

3) Connect the 3 vacuum hoses to the vacuum pipe.

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4) Temporarily tighten the harness brackets to the inlet manifold in the order shown in the diagram.

5) Final tighten the harness brackets to the inlet manifold in the order shown in the diagram.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) cylinder head cover installation".

1. Injector ID Code programming

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds.

2. ECM learned value clear

1) Turn ON the ignition switch.

2) Select the scan tool item.

3) Perform the ECM learned value clear by following the on-screen instructions.

4) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.

3. Clear Learned Value (Fuel Mass Observer)

1) Turn ON the ignition switch.

2) Select the scan tool item.

3) Perform Clear Learned Value (Fuel Mass Observer) by following the on-screen instructions.

4) After Clear Learned Value (Fuel Mass Observer) is complete, turn OFF the ignition switch for 30 seconds.